Service Manual
Contents
1. e Before the liquid gasket dries install the differential side oil seal See procedure 23 c Using the 8 bolts install the differential carrier cover Torque 20 6 N m 210 kgf cm 23 INSTALL DIFFERENTIAL SIDE OIL SEAL SST 09636 20010 a Apply MP grease No 2 to the lip of the carrier oil seal C137249 C137976 C139807 24 25 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD b Using the SST and a hammer drive in a new carrier oil seal up to the edge surface of the seal attachment part INSPECT TOTAL PRELOAD a Using a torque wrench and a deep socket wrench inspect the total preload activation torque while the drive pinion and ring gear teeth are in contact Standard 0 69 to 1 07 N m 7 03 to 10 9 kgf cm INSTALL FRONT DIFFERENTIAL CARRIER COVER BREATHER PLUG a Install the breather plug to the carrier cover Torque 11 3 N m 115 kgf cm INSTALLATION 1 INSTALL FRONT DIFFERENTIAL BRACKET RR a Using the 7 bolts install the front differential bracket RR to the front differential carrier Torque 76 N m 775 kgf cm INSTALL FRONT DIFFERENTIAL MOUNT CUSHION NO 1 a Using the 3 bolts install front differential mount cushion No 1 to front differential mount No 1 Torque 76 N m 775 kgf cm INSTALL FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET a Using the 4 bolts install the front differential carrier supp2. 139807 a Using SST and a press install the differential drive pinion b Using SST install the companion flange c Using the SST and a torque wrench tighten the lock nut Torque 118 N m 1200 kgf cm 17 MEASURE DIFFERENTIAL DRIVE PINION PRELOAD a Measure the preload of the drive pinion If the preload is not within the specified range select a shim for preload adjustment and adjust Product Number Thickness mm 90045 64533 1 65 90045 64534 1 70 90045 64535 1 75 90045 64536 1 80 90045 64537 1 85 90045 64538 1 90 90045 64539 1 95 90045 64540 2 00 90045 64541 2 05 90045 64542 2 10 90045 64543 2 15 90045 64544 2 20 90045 64545 2 25 90045 64546 2 30 90045 64547 2 35 DF 25 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD 139777 139758 0000 0 139783 139782 Product Number Thickness mm 90045 64548 2 40 90045 64549 2 45 18 19 20 REMOVE FRONT DRIVE PINION COMPANION FLANGE FR SST 09330 87301 09510 87301 a Using the SST remove the lock nut and the plate washer b Using the SST remove the companion flange INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL SST 09636 20010 a Apply MP grease No 2 to the lip of the carrier oil seal b Using
3. C139758 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD C139759 139760 C139761 C088550 12 REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL a Using the SST remove the oil seal SST 09308 10010 NOTICE Apply grease to the threads and tip of the SST center bolt before use 13 REMOVE DIFFERENTIAL DRIVE PINION a Using a press remove the differential drive pinion 14 REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING RR a Remove the tapered roller bearing RR inner race from the differential carrier b Remove the drive pinion bearing spacer and shim 15 REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING FR a Using the SST and a press remove the tapered roller bearing FR inner race from the drive pinion 16 REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING FR a Using a brass bar and a hammer lightly and uniformly tap on the tapered roller bearing FR outer race to remove it DF 16 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD C088551 SST C139762 Matchmarks C135701 C137301 17 18 19 20 REMOVE FRONT DRIVE PINION TAPERED ROLLER BEARING RR a Using a brass bar and a hammer lightly and uniformly tap on the tapered roller bearing RR outer race to remove it REMOVE FRONT DIFFERENTIAL CASE BEARINGS SST 09502 10012 a Remove the
4. shim b Using the SST remove the LH side bearing and the RH side bearing NOTICE As a reference for assembly the shims should be stored separately in for the ring gear back side and tooth side NOTICE e Apply grease to the threads and tip of the SST center bolt before use REMOVE DIFFERENTIAL RING GEAR a Secure the differential case in the vise between aluminum plates NOTICE Do not tighten the vise too firmly b Put match marks on the ring gear and the differential case c Remove the 8 bolts DISASSEMBLE THE DIFFERENTIAL CASE ASSEMBLY a Remove the parts listed below from the differential case assembly NOTICE e When removing the parts identify the installation position on the case differential e Store the gear and washer differential side gear thrust as a set Do not mix up the gears and washer differential side gear thrusts 1 Differential pinion shaft 1 in the diagram 2 Differential pinion gear 2 pieces 2 in the diagram 3 Front differential side gear thrust washer No 1 2 pieces 3 in the diagram 4 Differential side gear 2 pieces 4 in the diagram C135702 C135703 C135704 C088552 C088553 21 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD INSPECT DIFFERENTIAL CASE ASSEMBLY a Pinion differential drive gear differential ring 1 Visually inspect parts A B and C as shown in the diagram Standar
5. that the gear rotates smoothly HINT Slide Gear Thrust Washer No 1 Types Product Number Thickness mm 41361 87501 0 80 41361 87705 0 85 41361 87506 0 90 41361 87507 1 00 Matchmarks C135701 SST C139806 INSTALL DIFFERENTIAL RING GEAR a b Wipe off any grease or moisture from the ring gear contact surface of the differential case Secure the differential case in the vise between aluminum plates NOTICE Do not tighten the vise too firmly Clean the threaded holes of the differential case Wipe off any grease or moisture from the ring gear contact surface of the differential case Align the match marks on the differential case and the ring gear and install the ring gear NOTICE Align the bolt holes of the differential case and the threaded holes of the ring gear Tighten the 8 set bolts Torque 83 4 N m 849 kgf cm NOTICE e Wait until the ring gear has fully cooled off before tightening the bolts e Tighten the bolts in cross diagonal order Tighten gradually in several passes INSTALL FRONT DIFFERENTIAL CASE SST a 09309 87201 Using the SST and a press press the LH and RH bearings into the differential case CAUTION If the bearing is damaged replace it with new one NOTICE e Align the SST with the center of the differential case INSTALL DIFFERENT
6. 0 15 90045 64319 0 20 90045 64320 0 25 90045 64321 0 50 Clans g Remove the lock nut h Remove the plate washer and companion flange i Using the SST install the tapered roller bearing into the pinion NOTICE e Press in the bearing by pushing its inner side e If either the front or rear bearing is damaged replace them both as a set e When replacing the drive pinion replace it with the ring gear as a set 139779 j Using the SST and a press install the pinion to the differential Carrier NOTICE Do not install the bearing spacer and shim for preload adjustment O0000 C139780 DF 19 C139781 139782 SST 139777 C137301 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD k Using the SST and a press install the companion flange NOTICE Do not assemble the type T oil seal I Install the plate washer and lock nut m To work in the bearing turn the flange several times forward and backward ADJUST DIFFERENTIAL DRIVE PINION PRELOAD SST 09330 87301 a Using the SST and a torque wrench gradually tighten the lock nut to the preload standard Standard 0 59 to 0 98 N m 6 0 to 10 0 kgf cm INSTALL FRONT DIFFERENTIAL CASE NOTICE e When installing the side gear t
7. DF 11 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD REMOVAL 1 N oO a F Y DN ed 10 11 12 13 14 15 16 17 18 19 DRAIN DIFFERENTIAL OIL a Remove the differential filler plug and gasket b Remove the drain plug and gasket and drain the oil c Install the drain plug and a new gasket Torque 30 N m 306 kgf cm REMOVE FRONT TIRE REMOVE ENGINE UNDER COVER REMOVE ENGINE UNDER COVER RR RH REMOVE ENGINE UNDER COVER RR LH REMOVE FRONT AXLE HUB NUT LH See page DS 5 REMOVE FRONT AXLE HUB NUT RH a Perform the same procedure for the RH side as for the LH side REMOVE TIE ROD END LH See page DS 5 REMOVE TIE ROD END RH HINT Perform the same procedure for the RH side as for the LH side REMOVE FRONT STABILIZER LINK ROD See page SP 14 DISCONNECT FRONT SUSPENSION LOWER ARM NO 1 LH See page DS 5 DISCONNECT FRONT SUSPENSION LOWER ARM NO 1 RH HINT Perform the same procedure for the RH side as for the LH side DISCONNECT FRONT AXLE HUB LH See page DS 5 DISCONNECT FRONT AXLE RH HINT Perform the same procedure for the RH side as for the LH side REMOVE FRONT DRIVE SHAFT ASSEMBLY LH See page DS 6 REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT Perform the same procedure for the RH side as for the LH side REMOVE FRONT SUSPENSION CROSS MEMBER LWR See page PR 3 REMOVE FRONT PROPELLER SHAFT ASSEMBLY See page PR 3 S
8. IAL CASE ASSEMBLY a Install the differential case to the differential carrier C137412 C137410 Front Differential Case Shim Types b DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD Install using the same parts as those disassembled when removing only the shims for the back side of the gear differential ring HINT Check the shims If the shims are worn or scratched install a new shim of the same thickness ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH a b Set the dial indicator at a right angle to the gear Secure the flange S A drive pinion companion and move the gear to measure the backlash NOTICE Apply hypoid gear oil to each part Standard 0 10 to 0 17 mm HINT Select and install a shim so that the backlash of the ring gear falls within the range of standard values Product Number Thickness mm 90045 64598 1 30 90045 64599 1 35 90045 64600 1 40 90045 64601 1 45 90045 64602 1 50 90045 64603 1 55 90045 64604 1 60 90045 64605 1 65 90045 64606 1 70 90045 64607 1 75 90045 64608 1 80 Front Differential Case Shim Types 10 DIFFERENTIAL CASE NO 1 PLAY ADJUSTMENT a Measure the play of the differential carrier and the radial ball bearing on the differential ring gear tooth surface side HINT Select shims for use in the direction of the differential case thrust so that the play is w
9. UPPORT FRONT DIFFERENTIAL CARRIER ASSEMBLY a Support the front differential carrier assembly with a transmission jack NOTICE As the front differential carrier assembly is heavy be sure that it is securely supported with the transmission jack DF 12 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD C136011 C136916 C137249 20 REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY a Remove the bolt and disconnect front differential mount cushion No 1 from the front suspension cross member b Remove the 2 bolts then remove the front differential carrier assembly with bracket NOTICE Do not lose the front differential carrier assembly e When removing the front differential carrier assembly there is a possibility of leakage of residual oil 21 REMOVE FRONT DIFFERENTIAL CARRIER SUPPORT BRACKET a Remove the 4 bolts then remove the front differential carrier support bracket from the front differential carrier 22 REMOVE FRONT DIFFERENTIAL MOUNT CUSHION NO 1 a Remove the 3 bolts then remove front differential mount cushion No 1 from front differential mount No 1 23 REMOVE FRONT DIFFERENTIAL BRACKET RR a Remove the 7 bolts then remove the front differential bracket RR from the front differential carrier DISASSEMBLY 14 REMOVE FRONT DIFFERENTIAL CARRIER COVER BREATHER PLUG a Remove the breather plug from the car
10. al drive pinion protrusion adjustment Product Number Thickness mm 90045 64318 0 15 90045 64319 0 20 90045 64320 0 25 90045 64321 0 50 12 REMOVE DIFFERENTIAL CASE NO 1 a Remove rear differential case No 1 and the shim 13 REMOVE FRONT DRIVE PINION COMPANION FLANGE FR SST 09330 87301 09510 87301 DF 23 C139755 A C139758 139760 C139761 14 15 16 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD a Using the SST secure the companion flange FR b Remove the lock nut and the plate washer c Using the SST remove the companion flange FR NOTICE Apply grease to the threads and tip of the SST center bolt before use REMOVE DIFFERENTIAL DRIVE PINION a Using a press remove the differential drive pinion b Remove the tapered roller bearing from the differential carrier INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER a Install a new bearing spacer and shim same as the one removed to the drive pinion HINT Check the shims If the shims are worn or scratched install a new shim of the same thickness INSTALL DIFFERENTIAL DRIVE PINION SST 09330 87301 09257 87202 09350 87202 DF 24 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD O0O000 C139780 N C139782 C139777
11. d There is no notable wear or damage b Shaft differential pinion pinion differential gear differential side 1 Visually inspect parts A B C D E and F as shown in the diagram Standard There is no notable wear or damage c CASE DIFFERENTIAL 1 Visually inspect parts A B C D and E as shown in the diagram Standard There is no notable wear or damage REASSEMBLY 1 INSTALL FRONT DRIVE PINION TAPERED ROLLER BEARING FR SST 09950 60010 a Using the SST and a press press in the tapered roller bearing FR outer race INSTALL FRONT DRIVE PINION TAPERED ROLLER BEARING RR SST 09950 60010 a Using the SST and a press press in the tapered roller bearing RR outer race INSTALL DIFFERENTIAL DRIVE PINION SST 09257 87202 09330 87301 09530 87504 09350 87202 a Install the tapered roller bearing b Install the SST c Install the companion flange and plate washer DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD DF 18 d Using the SST tighten the lock nut to the specified torque Torque 118 N m 1200 kgf cm e Install the SST C139777 f Select the shims so that A in the diagram becomes the standard value Standard 0 5 0 05 mm HINT PMD pinion mounting distance HINT Shim Selection Table for adjustment of differential drive pinion protrusion Product Number Thickness mm 90045 64318
12. hrust washer No 1 side gear pinion gear or other parts make sure that there is no dirt or foreign matter on the parts such as dust or cutting powder e When replacing either the side gear or the pinion gear be sure to replace the side gear and the pinion gear together as a set Apply gear oil to the rotating and moving parts a Install the parts listed below to the the differential case HINT e Differential pinion shaft 1 in the diagram e Differential pinion gear 2 pieces 2 in the diagram e Front differential side gear thrust washer No 1 2 pieces 3 in the diagram e Differential side gear 2 pieces 4 in the diagram 1 Apply oil to the differential side gear and side gear thrust washer No 1 and install them to the differential case 2 Apply oil to the differential pinion and install it to the differential case 3 Apply oil to the differential pinion shaft and insert it into the differential case Lubricants Differential hypoid gear oil SAESOW 90 API category GL5 DF 20 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD ZD07930 b Install a dial indicator at a right angle to the edge of the tooth surface of the pinion gear Secure the drive pinion against the differential case and check the backlash Standard 0 025 to 0 10 mm Use the same sized side gear thrust washer No 1 in order to be able adjust the backlash of the side gear to within the standard value and to ensure
13. ions on the ring gear circumference REMOVE DIFFERENTIAL CASE NO 1 a Remove rear differential case assembly and the shim INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH a Secure the differential case in a vise NOTICE Do not tighten the vise too firmly DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD DF 14 b Install a dial indicator at a right angle to the edge of the tooth surface of the side gear shaft c Secure the pinion gear to the differential case and turn the side gear to check the side gear backlash Standard 0 025 to 0 10 mm C123386 9 INSPECT TOTAL PRELOAD a Using a torque wrench and a deep socket wrench inspect the total preload activation torque while the drive pinion and ring gear teeth are in contact Standard T 0 69 to 1 07 N m 7 04 to 10 9 1kgf cm 10 REMOVE DRIVE PINION COMPANION FLANGE NUT SST 09330 00021 09213 58013 a Using a chisel and a hammer unstake the lock nut 61990807 b Using the SST secure the companion flange FR c Using a deep socket wrench remove the companion flange nut NOTICE e When removing the nut completely unstake it e Do not damage the threads of the drive pinion 11 REMOVE FRONT DRIVE PINION COMPANION FLANGE FR SST 09510 87301 C139755 a Using the SST remove the companion flange FR NOTICE Apply grease to the threads and tip of the SST center bolt before use
14. ithin the specified value Product Number Thickness mm 90045 64598 1 30 90045 64599 1 35 90045 64600 1 40 90045 64601 1 45 90045 64602 1 50 90045 64603 1 55 90045 64604 1 60 90045 64605 1 65 DF 22 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD Product Number Thickness mm 90045 64606 1 70 90045 64607 1 75 90045 64608 1 80 11 INSPECT TOOTH CONTACT BETWEEN DIFFERENTIAL RING GEAR AND DRIVE PINION a Apply a light coat of red primer uniformly to the tooth surface side of the ring gear and turn the ring gear several times forward and backward The pattern of the red primer indicates the tooth contact position Normal Gear Contact Heel Contact Face Contact Select The Front Differential Case Washer To Allow The Drive Pinion To Come Close To The Differential Ring Gear Toe Contact Flank Contact Select The Front Differential Case Washer To Allow The Drive Pinion To Avoid Contact With The Differential Ring Gear C089686J01 NOTICE Check the contact state at 4 locations on the differential ring gear circumference b If the tooth alignment is off use the appropriate shim selected from the table to adjust the drive pinion protrusion and re install NOTICE In the case of face contact or flank contact the error may D F be adjustable within the range of standard backlash values HINT Shim Selection Table for differenti
15. orm the same procedure for the RH side as for the LH side CONNECT FRONT SUSPENSION LOWER ARM NO 1 LH See page DS 10 CONNECT FRONT SUSPENSION LOWER ARM NO 1 RH HINT Perform the same procedure for the RH side as for the LH side INSTALL FRONT STABILIZER LINK ROD See page SP 15 CONNECT TIE ROD END LH See page DS 10 CONNECT TIE ROD END RH HINT Perform the same procedure for the RH side as for the LH side INSTALL FRONT AXLE HUB NUT LH See page DS 10 INSTALL FRONT AXLE HUB NUT RH HINT Perform the same procedure for the RH side as for the LH side INSTALL FRONT DISC ADD DIFFERENTIAL OIL See page DF 3 INSTALL ENGINE UNDER COVER RR RH WITH ENGINE UNDERCOVER RR Rh INSTALL ENGINE UNDER COVER RR LH WITH ENGINE UNDERCOVER RR LH DF 29 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD 23 INSTALL ENGINE UNDER COVER 24 INSTALL FRONT TIRE Torque 103 N m 1050 kgf cm
16. ort bracket to the front differential carrier Torque 76 N m 775 kgf cm SUPPORT FRONT DIFFERENTIAL CARRIER ASSEMBLY a Using the transmission to support the front differential carrier assembly with bracket lift up to the installation position NOTICE e As the front differential carrier assembly is heavy be sure that it is securely supported with the transmission jack Do not damage the attachment surfaces when installing the front differential carrier assembly Do not lose the front differential carrier assembly DF 28 DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD ei C137248 5 10 11 12 13 14 15 16 17 18 19 20 21 22 INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLV a Using the 2 bolts install the front differential carrier support bracket to the front suspension cross member Torque 41 7 N m 425 kgf cm b Using the 2 bolts install the front differential mount cushion No 1 to the front suspension cross member Torque 41 7 N m 425 kgf cm INSTALL FRONT PROPELLER SHAFT ASSEMBLY See page PR 4 INSTALL FRONT SUSPENSION CROSS MEMBER LWR See page PR 4 INSTALL FRONT DRIVE SHAFT ASSEMBLY LH See page DS 10 INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT Perform the same procedure for the RH side as for the LH side INSTALL FRONT AXLE HUB LH See page DS 10 INSTALL FRONT AXLE HUB RH HINT Perf
17. rier plug 2 REMOVE DIFFERENTIAL SIDE OIL SEAL a Using the SST remove the right and left side gear shaft oil seal SST 09308 00010 3 REMOVE FRONT DIFFERENTIAL CARRIER COVER a Remove the 8 bolts b Using a brass bar and a hammer lightly tap on the differential carrier cover to remove it NOTICE e Place the brass bar against the ribs of the carrier cover e Do not damage the contact surfaces of the differential carrier 4 SECURE DIFFERENTIAL CARRIER ASSEMBLY SST 09219 87701 09219 87202 DF 13 C139756 137270 C137410 a b DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD Install the SST to the front differential carrier assembly Secure the front differential carrier assembly to the SST INSPECT RUNOUT OF DIFFERENTIAL RING GEAR a b Install a dial indicator at a right angle to the back side of the ring gear Check the runout of the ring gear by turning the companion flange FR Maximum limit 0 10 mm HINT If the runout exceeds the specified maximum value remove the ring gear and check the case runout INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH a b Install a dial indicator at a right angle to the edge of the tooth surface of the ring gear Secure the companion flange FR by hand and move the ring gear to check the backlash Standard 0 10 to 0 17 mm NOTICE Check the backlash at 3 or more locat
18. the SST and a press tap in a new carrier oil seal Make sure that the seal is installed to the standard value Standard 0 5 0 5 mm from the carrier end face INSTALL FRONT DRIVE PINION COMPANION FLANGE FR SST 09257 87202 09330 87301 09350 87202 a Using the SST and a press install the companion flange DIFFERENTIAL FRONT DIFFERENTIAL CARRIER ASSEMBLY 4WD DF 26 b Using the SST and a torque wrench tighten the lock nut Torque 118 N m 1200 kgf cm C139777 c Using a chisel and a hammer stake the companion flange nut 21 INSTALL DIFFERENTIAL CASE NO 1 a Install differential case No 1 and the shim to the differential carrier 22 INSTALL DIFFERENTIAL CARRIER COVER a Using a scraper and wire brush clean the liquid gasket attached to the differential carrier and the differential carrier cover Then remove any oils using cleaning fluid or equivalent ZK07449 b Apply the liquid gasket to the cover and install the cover to the differential carrier Make sure that there are no gaps in the liquid gasket before installing the cover to the carrier NOTICE e Ifthe liquid gasket dries before the cover is installed remove and re apply the liquid gasket e After installing the cover to the differential carrier wait at least 1 hour before filling with oil or driving the vehicle In addition avoid rapid acceleration 0136379 deceleration for at least 12 hours
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